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16091641Topic7TotalProductiveMaintenance (TPM)
16091641Topic7TotalProductiveMaintenance (TPM)
16091641Topic7TotalProductiveMaintenance (TPM)
Productive
7 Maintenance
(TPM)
LEARNING OUTCOMES
By the end of the topic, you should be able to:
1. Explain Total Productive Maintenance (TPM);
2. Describe the eight pillars of TPM;
3. Summarise eight major losses;
4. Review the strategies for implementing the five pillars of TPM; and
5. Describe the three stages of TPM implementation.
X INTRODUCTION
employee morale and job satisfaction. You will discover more about TPM as you
go through this topic. We will look at the definition of TPM, the eight pillars of
TPM, eight major losses, strategies for implementing the five pillars of TPM and
lastly, the three stages of TPM implementation. Enjoy your reading!
Figure 7.1 shows you how TPM evolved throughout the years. Productive
Maintenance includes equipment operatorsÊ participation and Predictive
Maintenance in Preventive Maintenance (PM).
Like Total Quality Control (TQC), which is a companywide total quality control,
TPM is equipment maintenance performed on a companywide basis. The term
TPM is defined to include the following:
Do you know that the word „total‰ in „ttotal productive maintenance‰ has three
meanings related to three important features of TPM? Let us look at them one by
one in Figure 7.2.
What are the goals of TPM? Well, apart from zero accidents, the other two goals
of TPM are zero breakdowns and zero defects. What happens when breakdowns
and defects are eliminated? When breakdowns and defects are eliminated,
equipment operation rates improve, costs are reduced, inventory can be
minimised and as a consequence, labour productivity increases.
84 X TOPIC 7 TOTAL PRODUCTIVE MAINTENANCE (TPM)
SELF-CHECK 7.1
The following are the eight pillars of TPM (see Figure 7.3). The first five, which
are (a) to (e), relate to effective equipment management which will be covered in
detail later in this topic.
TOPIC 7 TOTAL PRODUCTIVE MAINTENANCE (TPM) W 85
The first five pillars of TPM activities are similar to those of bringing up a
neglected child to its prime health. The illustration in Table 7.1 outlines the
similarities.
Table 7.1: The Similarities between TPM and Bringing Up a Neglected Child to
Its Prime Health
Child TPM
Elimination of Chronic Sickness Elimination of Major Losses
Daily Health Care Activities Autonomous Maintenance
Periodic Medical Checkups Schedule Maintenance
Education on Health Care Activities Training
Pre Natal Care Early Equipment Management
From the explanation in Table 7.1, it can be observed that the activities associated
with the pillars of TPM are essential for a holistic approach to maintenance
management. In the next section, we will look in detail at the first five pillars of
TPM.
86 X TOPIC 7 TOTAL PRODUCTIVE MAINTENANCE (TPM)
Loss Explanation
Shutdown Loss x Equipment stoppage for:
Maintenance; and
Inspection.
x Schedule shutdown for legal inspection.
Production Adjustment Loss x Set-up changes shutdown for subsequent
production time spent in „adjustment‰.
Equipment Failure Loss/Repair Parts x Shutdown for replacing worn out parts.
Change Loss
Process Failure Loss x Equipment shutdown resulting from:
Function stoppage stoppage occurs
unexpectedly.
Function Deterioration decrease of
equipment function.
Normal Production Loss/Start-up Loss x Total time spent to start-up, running in and
operating condition of the equipment to
stabilise or production.
x Total time spent to gradually shut-down
equipment or production.
Abnormal Production Loss/Minor x Machine stoppage or idling due to
Stoppages and Idling Loss temporary trouble (minor trouble):
Clogging;
Sensor defects; and
Non-conforming products.
Quality Defect Loss x Defects that are considered waste.
Reprocessing Loss x Reprocessed products need wasted time
and manpower.
This loss structure was devised by considering the eight losses from the aspect of
time. There are nine aspects to be considered as listed in Figure 7.5.
Let us look at the step to calculate it. To calculate net operating time,
subtract performance time losses from the operating time. Performance
time losses consist of normal production losses (production rate reductions
due to start-up, shutdown and changeover) and abnormal production
losses (production rate reductions due to abnormalities).
To calculate valuable operating time, add the time wasted reprocessing and
producing rejectable products and then subtract the result from the net
operating time.
(f) Availability
To calculate availability, subtract from calendar time the time lost during
shutdown (for planned maintenance and production adjustments) and the
time lost in major stoppages (equipment and process failures). Then, divide
the result by calendar time and multiply by 100 just like the equations.
It can be expressed as production (in tonne) per hour (t/h) or per day
(t/day). The actual production rate is expressed as an average. To calculate
it, divide the actual production (t) by the operating time.
The aim of this pillar is to develop operators to be able to take care of small
maintenance tasks, thus freeing up the skilled maintenance people to spend
time on more value added activities and technical repairs.
The operators are responsible for the upkeep of their equipment to prevent it
from deteriorating.
The planned maintenance will transform all our efforts from a reactive to a
proactive method and uses trained maintenance staff to help train the operators
to better maintain their equipment.
TOPIC 7 TOTAL PRODUCTIVE MAINTENANCE (TPM) W 93
For example, let us look at the difference in the maintenance requirements for a
car built in the 1970s compared to a car built in 2006. The 1970s car was tuned up
every 5,000km. The 2006 car is guaranteed for the first 50,000km. This change
was not brought about by accident or luck. The engineers carefully studied the
maintenance and engineering data, allowing changes to be made in the
automobile that reduced the amount of maintenance. The same can be true of
equipments in the production facility.
94 X TOPIC 7 TOTAL PRODUCTIVE MAINTENANCE (TPM)
Unfortunately, many companies do not keep the data that is necessary to make
these changes, either internally or through the Original Equipment Manufacturer
(OEM). As a result, unnecessary maintenance is performed on the equipment,
raising the overall maintenance cost.
You can visit this website, entitled „An Introduction to Total Productive
Maintenance (TPM)‰, to get extra information on TPM:
http://www.plant-maintenance.com/articles/tpm_intro.shtml
98 X TOPIC 7 TOTAL PRODUCTIVE MAINTENANCE (TPM)
ACTIVITY 7.1
4. List all the eight pillars of TPM. Describe briefly five pillars
that are related to effective equipment management.
For five days (9th to 13th) during the particular month, the
plant operated only at 800t/day due to some equipment
failure. On the 8th day, 100t of product was rejected. Apart
from the 9th to 13th day, the plant was operating at its
standard production rate. Draw the production rate against
day graph of the production profile and calculate the
following:
(i) Availability
(ii) Total production
(iii) Actual production rate
(iv) Performance rate
(v) Quality rate
(vi) Overall plant effectiveness
TOPIC 7 TOTAL PRODUCTIVE MAINTENANCE (TPM) W 99
Well done! You have just finished Topic 7. What can you summarise about this
topic?
Suzuki, T. (1993). New directions for TPM. Cambridge, MA: Productivity Press.